Manufacturing method of carbon fiber electric heating tape for water pipe heat preservation

Abstract

The invention relates to a manufacturing method of a carbon fiber electric heating tape for water pipe heat preservation, which comprises the following steps of: firstly, enabling a single wire or a flat cable of a carbon fiber electric heating wire and an electric wire which are wound on one or more wire storage discs and are used for manufacturing the carbon fiber electric heating tape to pass through a doubling shaft to form a line which is straightly close to the line, and winding the line on a winding shaft or a winding disc; wherein in the line doubling process of the branching segment type carbon fiber electric heating tape, the length of a carbon fiber electric heating wire needs to be measured, the carbon fiber electric heating wire is sequentially connected with a zero line or a live line through a copper wire buckle every time the length of one rated unit length electric power is reached, and then the line wound on a winding shaft or a winding disc passes through a pressing roller and is wound on the winding shaft or the winding disc; the carbon fiber electric heating tape is adhered to the middle position between the inner layer adhesive tape and the outer layer adhesive tape, and meanwhile, two side edges of the two adhesive tapes are adhered to form the carbon fiber electric heating tape which is wound on a finished tape reel.

Description

Technical Field

[0001] The invention patent relates to the technical field of electric heating and thermal insulation water pipes, and specifically to a method for manufacturing a carbon fiber electric heating belt for water pipe insulation. Background Art

[0002] At present, various water pipe insulation technologies are being used in homes, offices, commercial services and industrial hot water occasions. Especially in order to solve the current consumer pain point of cold water flowing continuously before the hot water arrives after turning on the faucet, and at the same time to solve the waste of tap water, electricity and gas in the country caused by the discharge of cold water, and the increase in carbon emissions, the market and the country need the emergence of better new insulation equipment and technologies to solve this problem. At present, the invention patent applied by the applicant, "A carbon fiber electric heating belt for water pipe insulation (patent number 2023230871171)", has proposed a new technical solution. This patent is a method for manufacturing such a carbon fiber electric heating belt for water pipes. It is a branch technology of this technology and constitutes another innovative content of the new technology.

[0003] In the prior art, there is already a patent for "an assembled electric heating insulation pipe" (patent number 201922119169.X) and a series of patents. A technical solution for an assembled carbon fiber electric heating insulation pipe has been proposed. There are some problems that need to be improved in terms of use effect, installation and production. This patent is specifically developed to address some major problems in manufacturing.

[0004] The main problems are:

[0005] 1. The existing technical solutions for the manufacture of assembled electric heating and heat preservation water pipes have the problem that carbon fiber electric heating pipes cannot be produced continuously and have high efficiency and low cost. Since the assembled electric heating and heat preservation water pipes are manufactured in units of sections of carbon fiber heat preservation pipes, the production and manufacture are very troublesome, the installation is also troublesome, and the labor is high and the efficiency is low.

[0006] 2. The existing technical solutions require a large number of core tube supports and other materials to produce carbon fiber electric heating tubes. It is necessary to continuously spirally wind the carbon fiber wire on the core tube, which consumes a lot of carbon fiber. In particular, short-sized carbon fiber electric heating tubes require longer carbon fibers to maintain the same electrical power per unit length, which will cause the problem of excessively high costs.

[0007] The present invention not only solves the above problems, but also brings the following advantages:

[0008] 1. The patent of this invention produces carbon fiber electric heating belts in a continuous manner. A belt can be hundreds of meters or even longer, which reduces labor costs and is highly efficient. The number of joints during installation is greatly reduced, and the installation process is simpler, which is convenient for the majority of water and electricians to master and ensure the installation quality during large-scale promotion.

[0009] 2. The patent of this invention reduces the cost. Only 2 meters of carbon fiber electric heating wire are used to manufacture 1 meter of carbon fiber electric heating belt. The cost of using carbon fiber is greatly reduced, and no core tube support and other materials are needed, which reduces the cost of raw materials.

[0010] 3. The processing cost of the patented carbon fiber electric heating element is reduced, which will increase the penetration rate of the final product market, allowing consumers to use products of this technology to solve pain points in life. At the same time, it also helps the country solve the "dual carbon" problem and find a way to implement it.

[0011] Invention patent content

[0012] The present invention discloses a method for manufacturing a carbon fiber electric heating tape for water pipe insulation, which is suitable for pasting on the outside of a water pipe. It is an electric heating tape using carbon fiber wire as a heating medium. It has an outer skin layer, an inner skin layer, a wiring layer, an inner skin layer, an outer rubber layer, and a release film layer combined together. There are two main types: one is a copper stranded wire divided into five wire systems of carbon fiber electric heating wire and copper stranded wire, namely, a neutral wire, a live wire, a ground wire, and a spare wire in the wiring layer. Because the carbon fiber electric heating wire must be divided into multiple wire segments and connected to the neutral wire or the live wire, it is called a multi-segment carbon fiber electric heating tape; the other is a wire system composed of three wire systems, namely, a carbon fiber electric heating wire, a ground wire, and a spare wire in the wiring layer. The carbon fiber electric heating wire is continuous, which is called a non-segmented carbon fiber electric heating wire tape. Both are continuously produced carbon fiber electric heating tapes. The present invention discloses a method for manufacturing these two types of carbon fiber electric heating tapes.

[0013] The present invention adopts the following technical solutions:

[0014] The manufacturing method of the carbon fiber electric heating tape for water pipe insulation mainly adopts the following two steps: one is paralleling: a total of five wires, namely, the carbon fiber electric heating wire and the neutral wire, the live wire, the ground wire, and the spare wire, or three wires, namely, the carbon fiber electric heating wire, the ground wire, and the copper wire of the spare wire, are paralleled into one line, that is, the various wires wound on one or more wire drums are passed through a paralleling shaft that can arrange the wires straight and close to form one line, and then wound onto the paralleling shaft or the paralleling drum; in the process of paralleling the line of the multi-segment carbon fiber electric heating tape composed of five wires, it is necessary to measure the length of the carbon fiber electric heating wire, and when each carbon fiber electric heating wire segment of a certain length with a rated unit length electric power is reached, it is necessary to connect with the neutral wire or the live wire in turn at this length point, so that after the entire segmented carbon fiber electric heating tape is manufactured, the unit length electric power of the entire tape is consistent and meets the use process requirements, and the multi-segment carbon fiber electric heating tape does not need segment connection due to special installation and use conditions. The second is tape covering: the wires wound on the doubling shaft or doubling drum are passed through a pressure roller and adhered between the outer tape and the inner tape under pressure to form a carbon fiber electric heating tape, which is then wound on the finished tape reel.

[0015] Furthermore, the carbon fiber electric heating wires and wires used are made of wires with plastic insulation sheaths. In the multi-segment carbon fiber electric heating belts with 5 types of wires, there are 1 carbon fiber electric heating wire, 1 neutral wire, 1 live wire, 1 ground wire, and 1 to 3 spare wires. The 3 types of non-segmented carbon fiber electric heating belts have 1 carbon fiber electric heating wire, 1 ground wire, and 1 to 2 spare wires, which are added to the wires in the form of single wires or arranged wires (multiple single-strand wires connected side by side), or the two can be mixed and used in one wire.

[0016] Furthermore, in the multi-segment carbon fiber electric heating tape with five kinds of wires, the arrangement of the carbon fiber electric heating wires and the electric wires is that the carbon fiber electric heating wires are arranged in the center of the line, the neutral wire and the live wire are on both sides, and the ground wire and the spare wire are outside; in the multi-segment carbon fiber electric heating tape with three kinds of wires, the carbon fiber electric heating wires are arranged in the center of the line, the ground wire and the spare wire are on both sides, and the tension of each wire must be adjusted to form a straight line in the end.

[0017] Furthermore, the wires are wound onto the winding shaft, and the wires are arranged on the paralleling shaft in a spirally close state; the wires are wound onto the winding reel, and the wires are arranged on the paralleling reel in an up-and-down stacking manner; the former method is used to form wires using a single carbon fiber electric heating wire, a neutral wire, a live wire, a ground wire, and a spare wire; the latter method is used to form a wire arrangement using the carbon fiber electric heating wire, a neutral wire, a live wire, a ground wire, and a spare wire, mainly for the purpose of arranging them neatly for the convenience of the next process.

[0018] Furthermore, the wires used, or the carbon fiber electric heating wires, and the single-strand wires arranged side by side are arranged in a cable (each single-strand wire is arranged in a cable, which is called a cable arrangement, and the carbon fiber electric heating wire and the wire are arranged in a full cable arrangement), the former is used in conjunction with the carbon fiber electric heating wire for paralleling, and the latter can be used alone for paralleling, thereby improving the efficiency and quality of the paralleling process. The wires of the single-strand wires and the cable arrangement are both plastic-coated copper stranded wires, and the carbon fiber electric heating wires are plastic-coated wires.

[0019] Furthermore, the length of the carbon fiber electric heating wire is measured, and the unit length electric power emitted by a certain length segment of the carbon fiber that meets the rated unit length electric power reaches the rated value when each length reaches 1 rated unit length electric power - different types of carbon fiber electric heating wires are connected to AC and DC power supplies. At this length point, it is connected to the neutral wire or the live wire in sequence, so that after the entire segmented carbon fiber electric heating belt is manufactured, the unit length electric power of the entire belt is consistent and meets the process requirements.

[0020] Furthermore, in the process of paralleling the multi-segment carbon fiber electric heating belt, the carbon fiber electric heating wire is connected to the neutral wire or the live wire by using a copper wire buckle to connect the carbon fiber electric heating wire and the neutral wire or the live wire at the notch of the cut plastic skin, and then wrapped with a heat shrink tube and heat-shrunk to make it flat.

[0021] Furthermore, the tapes used as the outer layer and the inner layer are: the outer layer tape is made of glass fiber reinforced polyvinyl chloride or polyester plastic film as the base material, and the inner layer tape is a tape with a release film, which is made of heat-resistant polyvinyl chloride, polyethylene, or polyester, and the release film layer is a plastic or paper base material.

[0022] Furthermore, the pressure roller acts on the inner and outer tapes to bond the lines to the outer layer, and acts on the edge strips on both sides, with a width of ≥10 mm, so that the inner and outer layers are tightly bonded together.

[0023] The patent of this invention has the following remarkable effects:

[0024] First, the patent of this invention can continuously produce two most commonly used carbon fiber electric heating tapes by using two steps. The process is simple, reducing labor costs by 45% and various equipment costs by 35%. At the same time, the installation of the carbon fiber heating tape can be done by laying one tape to the bottom. Compared with the processing of carbon fiber electric heating tubes section by section, it saves a lot of installation time, improves efficiency and reduces costs, and reduces the total cost by 35%.

[0025] Secondly, the carbon fiber electric heating belt of the present invention can be produced continuously, compared with the single intermittent production of carbon fiber electric heating tubes, and can reduce the variety and organize production in large quantities, with a larger production scale and improved processing efficiency.

[0026] Third, the patent of this invention greatly reduces the number of joints, which reduces the system failure rate by 25%, reduces the after-sales workload, improves the brand reputation, reduces the coordination cost and product price, and expands the market share of this product. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 This is a schematic diagram of single line paralleling;

[0028] Figure 2 It is a schematic diagram of combining a single wire with an electric wire arrangement;

[0029] Figure 3 This is a schematic diagram of the full wiring arrangement;

[0030] Figure 4 This is a schematic diagram of the line covering tape.

[0031] The present invention is further described in detail below in conjunction with the accompanying drawings and a specific method for manufacturing a carbon fiber electric heating belt.

[0032] like Figure 1 , Figure 2 , Figure 3 , Figure 4 As shown, a method for manufacturing a carbon fiber electric heating tape for water pipe insulation involves the following devices and equipment: a wire storage reel 1, a winding shaft 2, a paralleling shaft 3, wires 4, electric wires 5, carbon fiber electric heating wires 6, copper wire buckles 7, electric wire arrangements 8, a winding reel 9, a full arrangement 10, an inner layer tape reel 11, an inner layer tape 12, a pressure roller 13, a finished product reel 14, an outer layer tape reel 15, an outer layer tape 16, and a carbon fiber electric heating tape 17. Specific implementation method:

[0033] Example 1

[0034] like Figure 1 and Figure 4 , is a method for manufacturing a non-segmented carbon fiber electric heating belt by using a single wire and paralleling the wire:

[0035] The carbon fiber electric heating wire 6 and the electric wire 5 used as the ground wire and the spare wire are respectively wound on the three wire storage drums 1, with the carbon fiber electric heating wire 6 in the middle and the electric wires 5 used as the neutral wire and the spare wire on both sides, and pass through the paralleling shaft 3 under tension to form a straight line 4, which is then wound onto the winding shaft 2.

[0036] Wire 5 is made of polyvinyl chloride or silicone copper stranded wire with a wire diameter of 0.5 to 0.8 mm 2 The outer skin of the carbon fiber electric heating wire 6 is made of silicone material, and the core wire specification is 1K~6K.

[0037] The wire 4 wound on the winding shaft 2 is then adhered between the inner layer tape 12 and the outer layer tape 16 under the upper and lower pressure of the pressure roller 13 to form the inner layer, outer layer and release layer of the carbon fiber electric heating tape 17 respectively, and then wound on the finished product reel 14.

[0038] The core wire specification of the carbon fiber electric heating wire 6 is 1K to 18K, and the wire diameter of all the wires 5 is 0.3 to 0.8 mm. 2 The outer layer is a glass fiber reinforced polyvinyl chloride plastic film as the base material with a thickness of 0.02 to 0.15 mm. The outer rubber layer and the inner rubber layer are silicone pressure-sensitive adhesives. The inner layer is a flame-retardant polyester material with a thickness of 0.02 to 0.10 mm. The release film layer (6) is a paper-based substrate with a thickness of 0.05 to 0.10 mm.

[0039] Example 2

[0040] like Figure 2 and Figure 4 , is a method for manufacturing segmented carbon fiber electric heating belts by using a single wire and an electric wire arrangement line:

[0041] The carbon fiber electric heating wire 6 and two 2-wire electric wire arrangements 8 respectively wound on three wire storage disks 1 are used as neutral wire, live wire, ground wire and spare wire on both sides. The wires on both sides of the central carbon fiber electric heating wire 6 serve as neutral wire and live wire, and the outermost wires serve as ground wire and spare wire. After passing through the paralleling shaft 3 under tension, a straight line 4 of five wires is formed; the length of the carbon fiber electric heating wire 6 is measured during the winding process, and the carbon fiber electric heating wire segment is measured at each time when a certain length of a rated unit length of electric power is reached. At this length point, it is connected with the neutral wire or the live wire in turn at the notch of the core wire exposed by using a copper wire buckle 7 to press the core wire tightly, and then the line 4 is wound onto the winding shaft 2.

[0042] Then, the five kinds of wires 4 wound on the winding shaft 2 are adhered between the inner layer tape 12 and the outer layer tape 16 under the upper and lower pressure of the pressure roller 13 to form the inner layer, outer layer and release layer of the carbon fiber electric heating tape 17 respectively, and then wound on the finished product reel 14.

[0043] The core wire specification of the carbon fiber wire 6 is 1K to 12K, and the wire diameter of all the wires 5 and the wire arrangement wire 8 is 0.3 to 0.8 mm. 2 The outer layer is a glass fiber reinforced polyvinyl chloride plastic film as the base material with a thickness of 0.02 to 0.15 mm. The outer rubber layer and the inner rubber layer are acrylic pressure-sensitive adhesives. The inner layer is a heat-resistant polyvinyl chloride material with a thickness of 0.02 to 0.10 mm. The release film layer is a paper-based substrate with a thickness of 0.05 to 0.10 mm.

[0044] Example 3

[0045] like Figure 3 and Figure 4 , is a method for manufacturing a multi-segment carbon fiber electric heating belt using a full-line cable:

[0046] The full array of wires 10 are respectively wound on a wire storage disk 1, with the carbon fiber electric heating wire 6 in the center, the wires on both sides serve as the neutral wire and the live wire, and the outermost wire serves as the ground wire and the spare wire. After passing through the paralleling shaft 3 under tension, a straight line 4 is formed; during the winding process, the length of the carbon fiber electric heating wire 6 is measured, and at each carbon fiber electric heating wire segment that reaches a rated unit length of electric power, it is connected with the neutral wire or the live wire at the exposed core wire gap at this length point in turn, and the core wire is pressed tightly with a copper wire buckle 7, and then the line 4 is wound onto the winding shaft 2.

[0047] Then, the five kinds of wires 4 wound on the winding shaft 2 are adhered between the inner layer tape 12 and the outer layer tape 16 under the upper and lower pressure of the pressure roller 13 to form the inner layer, outer layer and release layer of the carbon fiber electric heating tape 17 respectively, and then wound on the finished product reel 14.

[0048] The core wire specification of the carbon fiber wire 6 is 1K to 12K, and the wire diameter of all the wires 5 and the wire arrangement wire 8 is 0.3 to 0.8 mm. 2 The outer layer is a glass fiber reinforced polyvinyl chloride plastic film as the base material with a thickness of 0.02 to 0.15 mm. The outer rubber layer and the inner rubber layer are acrylic pressure-sensitive adhesives. The inner layer is a heat-resistant polyvinyl chloride material with a thickness of 0.02 to 0.10 mm. The release film layer is a paper-based substrate with a thickness of 0.05 to 0.10 mm.

[0049] It should be stated that the above examples are only specific implementation examples of the patent of the present invention. Of course, those skilled in the art can make changes and modifications to the patent of the present invention. If these modifications and variations fall within the scope of the claims of the patent of the present invention and its equivalent technology, they should be considered to be within the scope of protection of the patent of the present invention.

Claims

1. A method for manufacturing a carbon fiber electric heating belt for water pipe insulation, characterized in that: First, a single line or a row of carbon fiber electric heating wires (6) and electric wires (5) wound on one or more wire storage reels (1) are passed through a wire-joining shaft (3) to form a line (4) in which the lines are straight and close to each other, and then the line is wound on a winding shaft (2) or a winding reel (9). In the process of joining the line (4) of the segmented carbon fiber electric heating belt, the length of the carbon fiber electric heating wire (6) is measured. When the length reaches a rated unit length of electric power, the carbon fiber electric heating wire (6) is connected to the neutral line or the live line (5) in turn. Then, the line (4) wound on the winding shaft (2) or the winding reel (9) is adhered to the middle position between the outer skin layer tape (12) and the inner skin layer tape (16) through a pressure roller, and the side strips of the two tapes are bonded to form a carbon fiber electric heating belt (17), which is then wound on a finished product reel (14).

2. The method for manufacturing a carbon fiber electric heating tape for water pipe insulation according to claim 1, characterized in that: The selection of the carbon fiber electric heating wire (6) and the electric wire (5) is divided into a carbon fiber electric heating wire (6) in a segmented carbon fiber electric heating belt (17) and one electric wire (5) as a neutral wire, a live wire, and a ground wire, and 1 to 3 spare wires (5). The carbon fiber electric heating wire (6) is arranged in the center of the line (4), and the electric wires (5) on both sides are defined as a neutral wire and a live wire, and the ground wire and the spare wire are outside. There is no segmented carbon fiber electric heating belt (17). One carbon fiber electric heating wire (6) is arranged in the center of the line (4), one of the electric wires (5) is used as a ground wire, and 1 to 2 spare wires are arranged on both sides, all of which are added to the line (4) in the form of a single wire or a wire arrangement. The carbon fiber electric heating wire (6) is a wire with a plastic sheath, and the electric wire (5) and the wire arrangement (8) are plastic-coated copper stranded wires. The wires (5) and the carbon fiber electric heating wire (6) contained in the full arrangement (10) are all plastic-coated.

3. The method for manufacturing a carbon fiber electric heating tape for water pipe insulation according to claim 1, characterized in that: When a single carbon fiber electric heating wire (6) is used to form a line with a neutral wire, a live wire, a ground wire, and a spare wire (5), the line is arranged in a spirally close state on the winding shaft (2). When a full-line wire (10) consisting of the carbon fiber electric heating wire (6), the neutral wire, the live wire, the ground wire, and the spare wire is used to form a line (4), it is wound on the winding drum (9) in an up-and-down overlapping manner.

4. The method for manufacturing a carbon fiber electric heating tape for water pipe insulation according to claim 1, characterized in that: The length of the carbon fiber electric heating wire (6) is measured at each length reaching 1 rated unit length of electric power, which refers to a certain length of carbon fiber that meets the rated unit length of electric power of different types of carbon fiber electric heating wires when connected to a 220V civilian power supply. When this length point is reached, the carbon fiber electric heating wire (6) is connected to the neutral wire or the live wire in turn, that is, the carbon fiber electric heating wire (6) and the electric wire (5) serving as the neutral wire or the live wire are connected together with a copper wire buckle (7) at the gap where the carbon fiber electric heating wire (6) and the electric wire (5) serving as the neutral wire or the live wire are exposed.

5. The method for manufacturing a carbon fiber electric heating tape for water pipe insulation according to claim 1, characterized in that: The outer layer adhesive tape (15) is made of a glass fiber reinforced polyvinyl chloride plastic film as a base material, and the inner layer adhesive tape (12) is an adhesive tape with a release film, the base material is a heat-resistant polyvinyl chloride material, and the release film layer is a plastic or paper-type base material.

6. The method for manufacturing a carbon fiber electric heating tape for water pipe insulation according to claim 1, characterized in that: The electric wire (5) or the electric wire arrangement (9) is made of polyvinyl chloride or silicone copper stranded wire, and the wire diameter is 0.3 to 0.8 mm. 2 The outer skin of the carbon fiber electric heating wire (6) is made of silicone and polyvinyl chloride, the core wire specification is 1K~18K, the outer skin tape (16) is a glass fiber reinforced polyvinyl chloride plastic film with a thickness of 0.02~0.15mm, the inner skin tape (12) is a tape with a release film, the tape material is heat-resistant polyvinyl chloride and polyester material, the thickness is 0.02~0.10mm, the release film layer is a paper-based substrate with a thickness of 0.05~0.10mm, the width of the side strips on both sides where the inner skin tape (12) and the outer skin tape (15) are bonded is ≥10mm, the carbon fiber electric heating wire (6) is combined with the neutral wire and the live wire by a copper wire buckle (7), and the gap is exposed for 5~8mm, and the heat shrink tube (9) is longer than the gap by ≥10mm on both sides.

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